Aluminum ZL109
GB ZL109 · EN AC-48000 · JIS AC8B
ZL109 is a nickel-bearing eutectic Al-Si-Cu-Mg piston alloy from GB/T 1173, cross-referenced to AC8B, A390.0 and 336.0, with high-temperature strength similar to ANSI 339.0.
Reference datasheet — ZL109 is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the T6 condition
ZL109 tempers and conditions
ZL109 is supplied in 5 conditions, soft to hard. T6 is the default FabDigit quotes; the values on this page are for it.
Compare all 5 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
As fabricated | Untreated as-cast condition; used for low-duty castings or as the starting point before heat treatment. | 150 | 190 | 0.8 | 90 HB | 29 % IACS |
Cooled from hot working and naturally aged | Simple ageing without solution treatment — the low-cost GB/T 1173 condition for mass-produced pistons where dimensional stability matters more than peak strength. | 180 | 215 | 0.6 | 100 HB | 28 % IACS |
Cooled from hot working and artificially aged | Short low-temperature age used by some piston makers to raise hardness quickly while keeping distortion to a minimum. | 190 | 225 | 0.6 | 105 HB | 28 % IACS |
Solution heat treated and overaged (stabilized) | Overaged/stabilised for maximum dimensional and thermal stability when the part runs continuously above 250 °C; trades ~10 % strength for creep and growth resistance. | 195 | 235 | 1 | 105 HB | 30 % IACS |
T6Default Solution heat treated and artificially aged | Peak-strength condition (GB/T 1173 JT6) for high-load petrol and diesel pistons and other hot-running castings. | 225 | 265 | 0.8 | 115 HB | 27 % IACS |
What is ZL109?
ZL109 is a nickel-bearing eutectic Al-Si-Cu-Mg piston alloy from GB/T 1173, cross-referenced to AC8B, A390.0 and 336.0, with high-temperature strength similar to ANSI 339.0. It is used for permanent-mould cast pistons and compressor parts that must hold 225 MPa yield and 115 HB with service to 250 °C and 125 W/m·K conductivity. Elongation is 0.8 % and machinability rates 45, so PCD tooling is mandatory and the alloy is not a structural choice; ZL111 or A354.0 suit medium-strength structural castings better. ZL109 has a density of 2.68 g/cm³ (0.0968 lb/in³), lighter than 72% of aluminum grades. It melts at 525°C (977 °F). ZL109 has a yield strength of 225 MPa (32.6 ksi) and a tensile strength of 265 MPa (38.4 ksi) — stronger than 59% of aluminum grades. Elongation at break is 0.8% and the elastic modulus is 80 GPa (11.6 Msi).
What is ZL109 used for?
- High-performance engine pistons
- Diesel engine pistons
- Reciprocating compressor pistons
- Air-conditioning compressor components
- Cylinder liners and ring carriers
- Wear-resistant bushings and guides
Advantages
- High service temperature — 250°C (482 °F), better than 97% of aluminum grades
- Stiff — 80 GPa (11.6 Msi), better than 95% of aluminum grades
- Low embodied carbon — 10.5 kg CO₂/kg, better than 95% of aluminum grades
Limitations
- Limited ductility — 0.8%, worse than 97% of aluminum grades
- Limited formability — 5/100, worse than 94% of aluminum grades
- Low fracture toughness — 15 MPa·√m (13.7 ksi·√in), worse than 93% of aluminum grades
- Low electrical conductivity — 27 % IACS, worse than 86% of aluminum grades
- Needs corrosion protection — 40/100, worse than 75% of aluminum grades
ZL109 properties
Typical room-temperature values for ZL109-T6; bars are the position among aluminum grades.
Physical3
ZL109 has a density of 2.68 g/cm³ (0.0968 lb/in³), lighter than 72% of aluminum grades. It melts at 525°C (977 °F).
Mechanical12
ZL109 has a yield strength of 225 MPa (32.6 ksi) and a tensile strength of 265 MPa (38.4 ksi) — stronger than 59% of aluminum grades. Elongation at break is 0.8% and the elastic modulus is 80 GPa (11.6 Msi).
Thermal6
ZL109 is rated for continuous service to 250°C (482 °F). It conducts heat at 125 W/m·K (72.2 BTU/hr·ft·°F), worse than 72% of aluminum grades. Thermal expansion is 19.5 µm/m·K (10.8 µin/in·°F).
Electrical3
ZL109 conducts electricity at 27 % IACS, worse than 86% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is fair (40/100), worse than 75% of aluminum grades.
Sustainability4
Producing a kilogram of ZL109 takes about 150 MJ of energy and emits 10.5 kg of CO₂ — less than 97% of aluminum grades. Typical recycled content is 35%.
Manufacturability7
ZL109's machinability is fair (45/100, worse than 72% of aluminum grades); weldability poor (30/100); formability not recommended (5/100).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the aluminum family
Yield strength against density for every aluminum grade FabDigit runs. ZL109 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with ZL109
Is ZL109 easy to machine?
Machinable with PCD or diamond-coated carbide only — the eutectic Si is highly abrasive; use high speed, light feed and flood coolant, and expect short tool life with plain carbide.
Can ZL109 be welded?
Poor weldability: Cu + Mg promote hot cracking and porosity; if repair is unavoidable use TIG with 4047 (Al-12Si) filler, preheat 150–200 °C and re-age afterwards.
Can ZL109 be formed, bent or molded?
Permanent-mould (metal mould) gravity casting is standard; excellent fluidity and low shrinkage, but degas the melt and P-modify to refine primary/eutectic Si and avoid coarse Ni-Fe phases.
ZL109 chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| Sieutectic Si, usually P-modified | 11 – 13 | 12 |
| Cu | 0.5 – 1.5 | 1 |
| Mg | 0.8 – 1.3 | 1 |
| Niforms thermally stable aluminides | 0.8 – 1.5 | 1.1 |
| Feimpurity limit | ≤ 0.7 | |
| Mnimpurity limit | ≤ 0.2 | |
| Tiimpurity limit | ≤ 0.2 | |
| Znimpurity limit | ≤ 0.2 | |
| Others (total)total impurities, GB/T 1173 | ≤ 1 | |
| Al | balance |
What surface finishes work on ZL109?
Hard anodising (Type III) on crowns and ring grooves for wear; decorative anodising is dark and mottled, so shot blasting, tin/graphite coating or phosphating are the usual surface treatments.
Surface treatments FabDigit runs on aluminum parts — pick them in the quote configurator or call them out on the drawing. Each links to its datasheet in the surface-finish library (thickness, specs, call-out, material verdicts).
Organic Coating
Equivalent designations
Standards and trade names that resolve to Aluminum ZL109 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
How much does ZL109 cost?
ZL109 is a standard-cost aluminum ($$), cheaper than about 71% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
ZL109 — frequently asked
What is ZL109 used for?
ZL109 is typically used for high-performance engine pistons, diesel engine pistons, reciprocating compressor pistons, air-conditioning compressor components, cylinder liners and ring carriers and wear-resistant bushings and guides. In short: ni-strengthened piston alloy; highest hot hardness, 115 HB; abrasive, needs PCD tooling.
What is the yield strength of ZL109?
ZL109 has a typical yield strength of 225 MPa (32.6 ksi) and a tensile strength of 265 MPa (38.4 ksi) — stronger than 59% of aluminum grades. Strength varies by condition: see the 5 listed tempers.
Is ZL109 easy to machine?
Reasonably — machinability is rated fair (45/100, worse than 72% of aluminum grades). Machinable with PCD or diamond-coated carbide only — the eutectic Si is highly abrasive; use high speed, light feed and flood coolant, and expect short tool life with plain carbide.
Can ZL109 be welded?
Not readily — weldability is rated poor (30/100). Poor weldability: Cu + Mg promote hot cracking and porosity; if repair is unavoidable use TIG with 4047 (Al-12Si) filler, preheat 150–200 °C and re-age afterwards.
What surface finishes work on ZL109?
Hard anodising (Type III) on crowns and ring grooves for wear; decorative anodising is dark and mottled, so shot blasting, tin/graphite coating or phosphating are the usual surface treatments.
Can ZL109 be formed, bent or molded?
Permanent-mould (metal mould) gravity casting is standard; excellent fluidity and low shrinkage, but degas the melt and P-modify to refine primary/eutectic Si and avoid coarse Ni-Fe phases.
What is the maximum service temperature of ZL109?
ZL109 is rated for continuous use to about 250°C (482 °F). Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between ZL109-T6 and ZL109-F?
T6 is the default condition — peak-strength condition (GB/T 1173 JT6) for high-load petrol and diesel pistons and other hot-running castings. F: untreated as-cast condition; used for low-duty castings or as the starting point before heat treatment. Yield strength is 225 MPa in T6 versus 150 MPa in F.
How much does ZL109 cost?
ZL109 is a standard-cost aluminum ($$), cheaper than about 71% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- ASM Handbook Vol.2 — Properties and Selection: Nonferrous Alloys (339.0, 336.0) — ASM International (1990)
- JIS H5202 — Aluminium alloy castings (AC8B) — JSA (2010)
- Aluminum Association Pink Sheets — Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingot — The Aluminum Association (2018)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.